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Warranty Manual
Espar Products, Inc.
Tel: (905) 670-0960
(800) 387-4800
Fax: (905) 670-0728
www.espar.com
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Table of Contents
Policies
Warranty Policy Overview ......................................................................................................... 3
Warranty Period ......................................................................................................................... 4
What IS and IS NOT Covered under Warranty ......................................................................... 5
Heater Identification Plate ......................................................................................................... 6
Warranty Registration ................................................................................................................ 8
Dealer Requirements to perform Warranty Repairs ................................................................. 9
Procedures
Procedure Prior to Starting Warranty Work ............................................................................. 10
Procedure for Performing Warranty Work ............................................................................... 11
Procedure for Submitting Warranty Claims ............................................................................. 12
Espar’s Internal Procedure for Processing Warranty Claims .................................................. 14
Warranty Notification Form ...................................................................................................... 14
Warranty Authorization (WA) .................................................................................................. 14
Warranty Evaluation (WE) ....................................................................................................... 15
“Always Repair Heater” Policy ................................................................................................. 16
Procedure for Submitting a Heater to Espar for Repair (RR) .................................................. 16
New, Defective Parts or Heaters ............................................................................................. 17
Procedure for Returning Defective Goods (RA) ...................................................................... 17
Procedure for warranty appeal................................................................................................18
Flat Rate Labour Guide
Flat Rate Labour Guide ........................................................................................................... 19
AIRTRONIC 2 / 4 ..................................................................................................................... 20
B1LC compact ......................................................................................................................... 22
B / D3LC compact ................................................................................................................... 24
B / D5LC .................................................................................................................................. 26
AIRTRONIC 5 .......................................................................................................................... 28
D8LC ........................................................................................................................................ 30
HYDRONIC 4 / 5 SC with integrated fuel metering pump ....................................................... 32
HYDRONIC 4 / 5 SC with external fuel metering pump .......................................................... 34
HYDRONIC 5 S ....................................................................................................................... 36
HYDRONIC 5 Z ....................................................................................................................... 38
Hybernator II in Frame............................................................................................................40
Hybernator Compact...............................................................................................................41
Hybernator Aux Blower Kit......................................................................................................42
HYDRONIC 10......................................................................................................................... 44
HYDRONIC M II ...................................................................................................................... 46
HYDRONIC 16 / 24 / 30 / 35 ................................................................................................... 48
HYDRONIC L II ...................................................................................................................... 50
Tools and Equipment
Computer Diagnostic Tools ..................................................................................................... 52
Appendices
Appendix A:
Appendix B:
Appendix C:
Appendix D:
Appendix E:
Appendix F:
The Espar Limited Warranty .............................................................................. 54
Sample Warranty Tag ........................................................................................ 55
Sample Espar Shipping Label ........................................................................... 56
Warranty Notification Form ................................................................................ 57
Technician’s Checklist ....................................................................................... 58
Warranty Claim Appeal Form.............................................................................59
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Warranty Policy Overview
The purpose of the Espar warranty is to ensure that the end-user (customer) of Espar Products is
satisfied with the quality of their purchase. In order to provide customer satisfaction, Espar stands
behind its products as they leave Espar’s control.
This Espar Warranty Manual, and all policies and procedures within it, supersedes all previous
warranty manual revisions. It will remain valid until a new manual is released, or until further notice.
Any requests for dealer labour rate increases must be made in writing and forwarded to the Warranty
Department. Approval or denial will be decided upon review with the decision communicated back to
the dealer.
While the warranty is applicable to the end-user, it is administered and performed only through the
Espar network of trained dealers and distributors.
To this end, Espar will follow the procedures outlined in this manual in the processing and
administration of warranty claims.
For specific information please refer to the Espar Limited Warranty section as outlined in Appendix A
of this manual.
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Warranty Period
The warranty period of a heater is specified in years or in heater operating hours, beginning from the
date of installation, whichever is reached first. (Please see “What IS and IS NOT Covered under
Warranty” section on page 5 of this manual). If the installation date is not made known to Espar by
registering the heater within thirty (30) days of installation, or by providing proof of installation date at
time of warranty claim (i.e. installation invoice or ‘in-service’ document), the warranty period will begin
on the date of shipment from Espar’s North American warehouse.
IMPORTANT NOTE:
• Heaters must be installed within one (1) year of purchase date to be eligible for
warranty.
• Installation invoices or ‘in-service’ document provided to Espar must include
applicable model number(s) and serial number(s) of the heater(s) installed.
• Heater meant for truck application should not be transferred/installed for marine
application.
• Heater installation must be done by a customer or service provider who have been
trained and certified by Espar Heater trainers.
Replacement Parts
All replacement parts are warranted to be free from defects in material and/or workmanship for ninety
(90) days from the date of sale or the remainder of the original warranty period on the heater;
whichever is greater.
Special Tools
Special Tools (i.e. ISO Adapter, Fault Code Retrieval Device, EDiTH Adapters, etc.) are warranted to
be free from defects in material and/or workmanship for twelve (12) months from the date of sale
(from Espar’s North American warehouse).
The following warranty periods by model are:
Air Heaters
Heater Model
AIRTRONIC 2
AIRTRONIC 4
AIRTRONIC 5
B1LC compact
B / D3LC compact
B / D5LC
D8LC
Coolant Heaters
Heater Model
B / D5W
HYDRONIC 4
HYDRONIC 5
HYDRONIC 10
HYDRONIC M8 / M10 / M12
HYDRONIC 16 / 24 / 30 / 35
HYDRONIC L16 / L24 L30 / L35
* = whichever is reached first
Standard Warranty
2 years or 2000 hours*
2 years or 2000 hours*
2 years or 2000 hours*
2 years or 2000 hours*
2 years or 2000 hours*
1 year or 1000 hours*
1 year or 1000 hours*
Standard Warranty
2 years or 2000 hours*
2 years or 2000 hours*
2 years or 2000 hours*
1 year or 1000 hours*
2 years or 1500 hours*
1 year or 1000 hours*
1 year or 1000 hours*
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What IS and IS NOT Covered under Warranty
The purpose of Espar Warranty is to provide the end user (customer) of Espar heaters with protection
from defects in material and workmanship.
A. Items covered include:
PARTS
1. Timers, thermostats, mini controllers or other electronic temperature control products
provided by Espar
2. Electronic control units (ECU’s)
3. Glow pins
4. Fuel metering pumps
5. Heat exchangers and / or combustion chambers (burner)
6. Air blowers
7. Coolant pumps
8. Flame, overheat and temperature sensors
9. O-rings, gaskets, seals (excluding Hydronic D5 Coolant pump O-rings)
10. Wire Harnesses (only those provided by Espar are warranted; prior authorization is
required from Espar’s warranty department
SERVICE
1. Shipping costs associated with the authorized return of warranted parts from the Espar
Dealer/Distributor to Espar (only for shipments that contain parts specifically requested
by Espar).
2. To receive travel time to repair heaters installed on boats and/or off-highway heavy
equipment, the travel section must be completed on the warranty claim for consideration
of payment. Please note that Maximum Limits do apply.
B. Items not covered include but are not limited to:
PARTS
1. Heaters no longer covered within terms of warranty;
2. Wear and tear parts, including:
i. Glow plugs
ii. O-rings (Hydronic D5 Coolant pump)
iii. Clamps, clips, brackets
iv. Batteries
v. Coolant
vi. Atomizer screens
vii. Fuel system components (i.e. Fuel pickup pipe, fuel line, filters, etc.)
viii. Fuses
ix. Connectors, terminals and screws
x. Lamp bulbs
xi. Air ducting, Intake and exhaust tubing
3. Parts that malfunction due to improper installation, which may result from:
i. Inadequate air or coolant flow;
ii. Inadequate or restricted fuel flow;
iii. Inadequate voltage due to improper wiring upon installation;
iv. Inadequate protection from shock or vibration;
v. Inadequate protection from road spray or weather conditions.
4. Components that have been opened, tampered with or modified by parties other than
Espar.
5. Using non-standard parts or parts not approved by Espar in the installation.
6. Diagnosis or repairs completed when cause of the problem or failure is due to electrical
system problems outside the heater, excessive engine debris or empty fuel tanks or poor
quality fuel.
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7. Deterioration due to normal wear, corrosion, abuse, damage, accident, improper storage
or operation.
8. Costs incurred through an incorrect diagnosis, poor performance of the repair. This also
applies to corrections of installations that did not meet Espar specifications. In these
cases the costs incurred are to be charged to original installer.
SERVICE
1. Travel time by dealers/distributors traveling within their assigned territories except as
noted in A: SERVICE #2 above.
2. Shipping costs associated with the unauthorized return of warranted parts from the Espar
Dealer/Distributor to Espar Products.
3. Espar will not pay for return shipping cost to the Dealer/Distributor where parts are
deemed acceptable after testing.
Normal periodic heater maintenance (as outlined in each heater manual) shall be the
responsibility of the owner of the heater. A general guideline is to run the heater a minimum
of once ( 1 ) per month for fifteen (15) minutes all year round.
Heater Identification Plate
The Heater Identification Plate provides all of the heater information, which is required when filing a
warranty claim such as Heater Model Type, Part Number and Serial Number. This information must
be included on every warranty claim, so be sure to record it before any warranty repair work is
completed. Claims without serial numbers are subject to rejection.
Model Name:
AIRTRONIC, HYDRONIC or three or four digit Heater Model Name (i.e. D5LC).
In a three or four digit name, the following explanation may be helpful in understanding the Heater
Model Name:
First digit (indicates fuel type):
Second digit (indicates kilowatt heat output):
Third digit (indicates type of heater):
Fourth digit (further designation):
Alpha (D = diesel, B = gasoline)
Numeric (5 = 5 kilowatt, etc.)
Alpha (L = air heater, W = coolant heater)
Alpha (C = comfort)
Heater Model Name
Heater Model Number
Heater Serial Number
Fuel Type
Electrical Power Consumption
Maximum Heat Output
Operating Pressure
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NOTE: It is strongly advised that during the heater installation the
Duplicate Heater SN Label is placed in a clearly visible or
easily accessible location (such as on driver’s door etc)
Duplicate Heater Identification Plate (SN Label)
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Warranty Registration
A blue Warranty Registration notification is shipped with every heater. Please note there are several
important reasons why the warranty should be registered.
If a warranty registration is not received by Espar, the heater warranty period begins on the date the
heater is shipped from Espar’s North American warehouse. When the warranty is properly
registered, Espar can identify the date on which the heater was installed and / or put into service and
therefore begin the heater warranty period on that date. This effectively extends the warranty
period of the heater to the maximum time available.
Registering the warranty also serves the purpose of identifying the purchaser and original installation
of the heater since the warranty is non-transferable.
It also identifies the installing dealer so, if required and if necessary, any installation related problems
could be brought to the attention of the installer.
Espar recommends all dealers / distributors to register their customers’ warranty within 30 days of
installation by completing and submitting registration form via the internet on Espar’s website
(www.espar.com). Click on the “Warranty” link, then on the “Warranty Registration Coupon” link to
access the warranty registration.
Again, it is in the customer’s best interest that the warranty be registered to receive the full warranty
period allotted for their particular heater.
IMPORTANT NOTE:
If the warranty registration is not completed and received by Espar within thirty (30) days of
installation the heater warranty period begins on the date the heater is shipped from Espar’s
warehouse, unless other information is provided to Espar upon request.
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Dealer Requirements to Perform Warranty Repairs
To conduct warranty repairs and submit warranty claims, the following criteria must be met:
1. Possess and maintain certified technician/s who have undergone Espar Technical
Training (installation, diagnosing and troubleshooting) and Warranty Training.
2. Possess all tools required to install, maintain and service Espar products as outlined in
Tools and Equipment section of Espar manuals.
3. Possess at all times at least one copy of the current Espar Warranty Manual and all
applicable heater service manuals. The latest Espar Warranty Manual is available by
downloading directly from Espar’s website (www.espar.com)
4. Maintain sufficient inventory of parts, based on heater type serviced.
In order to access the Espar Online Warranty Claim Form at www.espar.com and to submit a
warranty claim, Espar will provide a username and password after all required information has been
received. At that time the Hourly Labour Rate is agreed upon and it is frozen for a year. Espar’s
Warranty Administrator must be notified in writing of labour rate increase. Approval or denial will be
decided upon the review and decision will be communicated back to the dealer by the Warranty
Administrator in e-mail format.
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Procedure Prior to Starting Warranty Work
As a member of the Espar distribution organization, you are expected to stand behind your work.
This includes properly specifying and installing heaters and instructing your customers on the proper
operation and maintenance of the heater and all related components or accessories. All heater
technical manuals are available for download at Espar’s website (www.espar.com).
A. Before starting any warranty repairs on the heater, please check (as appropriate) the following
(as suggested in the Technician’s Checklist (Appendix E)):
1. Electrical System
a) Are connections tight and free of corrosion?
b) Has proper gauge wiring been used for the length and amperage requirements for that
wiring?
c) Have any fuses or circuit breakers been activated?
d) Is power taken directly from the batteries and ground to the batteries?
2. Fuel System
a) Have proper diameter fuel lines been used?
b) Have proper length fuel lines been used?
c) Has a proper connection to the fuel supply been made?
d) Is the fuel flowing or has it gelled?
e) Are there restrictions in the fuel line?
f) Is the fuel metering pump properly aligned?
g) Is the fuel filter clogged?
h) Has an Espar fuel pick-up pipe been used, and is it the proper length and diameter?
3. Coolant flow or Air Flow System
a) Are there any obstructions in the system?
b) Is the heater system too large (or small) for the application?
c) Has proper coolant hose size or ducting size been used?
4. Total operating hours to-date (with EDiTH diagnostics).
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Procedure for Performing Warranty Work
As a member of the Espar distribution organization you are trained in the installation, troubleshooting
and repair of Espar heaters and systems and you have all of the necessary tools required to properly
diagnose heater functions.
Technical publications such as Technical Descriptions, Troubleshooting Guides and Parts Manuals
are available by downloading directly from Espar’s website (www.espar.com). Technical circulars are
issued periodically from Espar’s Technical Department. It is important to refer to current publications
while working on a heater. Special tools and test equipment are available for some heaters (please
refer to the Tools and Equipment section). If you have any questions, please contact Espar’s
Technical Department.
Once you have examined the heater for system or installation problems, as set forth in the preceding
section, and have determined that warranty work must be performed, follow the technical publications
and use your training and experience to correct the cause of the problem.
IMPORTANT NOTE:
Always ensure that the root cause of the problem is corrected, rather than simply correcting
the symptom(s) of the problem. For example: if a heater has overheated several consecutive
times and has been locked out (F15), do not simply reset the heater with the diagnostic unit.
Locate the source of the overheat problem and correct it.
Any part replaced under warranty must be tested as per current heater manuals test procedures to
confirm that it is defective before it is claimed. Parts that should be tested are, but are not limited to:
Glow Pins
Control Units
Fuel Metering Pumps
Temperature, Flame and Overheat Sensors
Combustion Air Blowers
Coolant Pumps
Thermostats and Timers
Mini Controllers
Wire Harnesses
Espar assumes that the technical repair is carried out without fault and economically, i.e. replacement
of only those parts that are defective, settlement of only those labour costs incurred (according to Flat
Rate Labour Guide). Duplicate expenses, for example two journeys because the spare part was not
available, cannot be claimed.
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Procedure for Submitting Warranty Claims
IMPORTANT NOTE:
After the warranty work has been performed and the heater is operating properly and it has been
determined that the problems were truly warranty problems and not due to improper application
specification, installation or operation; the procedure is as follows:
1. Affix an Espar Warranty Tag to all claimed parts. Fill out ALL the information indicated on the
tag: Dealer Stamp, Dealer Claim Number, Espar Part Number, Part Description, Heater
Name, Heater Part Number, Serial Number, Description of Defect and WE#. Each part must
be held for thirty (30) days AFTER the claim has been filed. Espar reserves the right to
inspect any or all parts, upon request. If any of these parts are not requested back by Espar
after the thirty (30) day period, the part may be disposed of.
Supplies of Warranty Tags (Appendix B) are supplied by Espar upon request and are
distributed through the main Espar authorized service branch.
IMPORTANT NOTE:
Should Espar request parts back, a WE# will be issued to the dealer. It is important to receive
all requested parts back as warranty claims are reviewed either at Espar or its parent
company, Eberspaecher. It is imperative that defective parts are available for testing and
evaluation.
2. A warranty claim must be submitted within thirty (30) days of the date of repair.
IMPORTANT NOTE:
If a new part is determined to be defective within ninety (90) days AFTER INSTALLATION, a
warranty claim should be filed as usual and the description of the problem should clearly state
“90 day warranty.” This coverage will even apply should the heater be out of warranty
however, no handling, labour or travel will apply in this case.
Please review the specific procedure below to file all warranty claims.
A. Go to Espar’s website (www.espar.com) and click the “Warranty” link, then the “Warranty
Claim” link. Only authorized Espar dealers can submit warranty claims through the secured
area of the Espar website.
B. Complete all information, including: Claimant Information, Espar MSD or Direct Dealer,
Claim Number, Date, WA# (Refer to WA# section of this Manual), Heater Model Number,
Heater Model Part Number (i.e. 25 1976), Heater Serial Number (same as Fabrik No.)
including all alphanumeric digits (i.e. 123456AE), Voltage (12V or 24V), Repair Date,
Application Type, Vehicle information (model, type and VIN), Installation Date and Registered
Owner Information (including name, address, city, province / state and postal / zip code).
IMPORTANT NOTE:
Warranty claims that are inaccurate (information does not correspond to the information
received for the warranty registration or sales records at Espar) will be on HOLD pending the
information required for clarification. If required information is not received within 10 days, the
associated claim will be rejected.
C. Describe the problem and repair in detail in the “Description of Problem” section; this includes
all fault codes (mandatory), and testing procedures and values. Please note: the description
of the troubleshooting should correspond to the relevant fault codes (entered in the fields
specified).
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D. Each claim automatically receives thirty (30) minutes for troubleshooting Operation Code A,
and thirty (30) minutes for heater function testing, Operation Code D.
E. In “Parts Required for Repair” section, indicate the quantity and choose Espar Part Number
and Description.
F. Choose the applicable Operation Code and Labour Time (as per the applicable Flat Rate
Labour Guide).
Example:
The AIRTRONIC D2 appears to start normally but then it shuts down and
attempts to restart. The diagnostic fault codes in memory are: AF 64; F1 64; F2
64 and F3 64. The flame sensor was removed, tested and found to be defective
(open circuit). The operations performed, according to the Flat Rate Labour
Guide were:
A
Troubleshoot
B230
Replace flame sensor
D
Function test
Total Time =
30 minutes
10 minutes
30 minutes
70 minutes
G. Indicate the total operating hours to-date (with EDiTH diagnostics).
H. To receive travel time for repair for heaters installed on boats and off-highway heavy
equipment, the travel section must be completed on the warranty claim for consideration of
payment. Please note maximum limits do apply.
IMPORTANT NOTE:
Espar must receive the warranty claim within thirty (30) days of the date of heater repair.
Claims submitted 30-60 days from the date of repair will not include an additional 20% markup
on parts for part handling. Claims submitted more than sixty (60) days from the date of repair
will be rejected. There will be no exceptions.
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Espar’s Internal Procedure for Processing Warranty Claims
Espar will make every effort to process warranty claims promptly providing all information is provided
as set out in this manual. Thus, Espar is committed to issuing credit for processed warranty claims
within thirty (30) days of receiving back the requested parts.
Warranty Notification Form
It is the dealer’s responsibility to respond to the warranty notice (Appendix D) within ten (10) business
days; If there is no response within this time period, Espar will permanently close and reject the claim.
Espar will not re-open this claim once this process has been complete.
When a warranty claim is processed, according to Espar’s existing warranty policy, the Dealer
submitting the claim and/or MSD/DD will receive notification based upon the following criteria:
Warranty Claim is ON HOLD: Extra information is required by Espar to process the warranty claim.
Adjustments were made to the submitted Warranty Claim: Labour time / rate requested was
incorrect; duplicate labour codes, authorization for excess time, labour or parts were not requested, or
installation date was incorrect.
Rejection of the Warranty Claim: The heater warranty period has expired; parts returned were
tested and found to be not defective; parts claimed were not covered under warranty; inadequate
parts return; duplicate warranty claim; vehicle owner is not the original registered owner; requested
information not returned within ten (10) business days; or unauthorized WA# used for warranty claim
that was not approved for a particular serial number, etc.
Acceptance of the Warranty Claim: The claim submitted meets all of the necessary criteria and is
being processed.
Please see Appendix D for the notice form.
Warranty Authorization (WA)
A warranty authorization number (WA#) will be issued only for claims that are abnormal or outside the
normal scope of the warranty manual. Please refer to the Flat Rate Labour Guide for the particular
heater in question to see the additional parts that are allowable under certain conditions. These are
identified by the shaded areas on the Flat Rate Labour Guide. Please request this WA# PRIOR to
submitting any claim by sending an email to Espar’s Warranty Administrator for authorization. The
email must include the serial number of the heater, the end user customer name, a detailed
description of the problem and tests performed and the main reason for the request. The WA request
will be approved or rejected by the Warranty Department at their discretion based on the supplied
information.
The warranty authorization number (WA#) issued by Espar pertains to one specific instance only and
is to be used when submitting the claim on-line. IT IS NOT A GENERIC NUMBER TO BE USED
LIBERALLY and if used as such will result in immediate warranty claim rejection.
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Warranty Evaluation (WE)
Every claimed part must be tagged and held for thirty (30) days following the submission of a warranty claim.
During this time frame Espar may request that a part or heater be returned to Espar for evaluation. In this
case the following procedures will apply:
1. When requesting parts and / or heaters back for evaluation, associated with a warranty claim, the
Warranty Administrator will issue a Warranty Evaluation (WE) reference number and contact the
customer of record (authorized Espar MSD / Direct Dealer) via email. It is the responsibility of the
MSD / DD to distribute this number to their sub-dealers. Upon receiving a WE#, all parts
corresponding to the given WE# must be returned within thirty (30) days.
PLEASE NOTE: If part is not received within this timeframe the corresponding claim will receive
NO handling. If the part is still not received within the following 30 days, the claim will be rejected
and closed permanently.
2. All paperwork and packaging must reference the WE number to avoid rejection. When any product
is returned without a WE number there will be a $50.00 administration charge to your account. NO
EXCEPTIONS WILL BE MADE.
3. Parts and heaters must be packaged securely to avoid damage in transit, as damaged parts/heaters
are not covered under warranty.
4. Ship via UPS ground (Air shipments will not be paid for by Espar).
5. All parts and heaters must be marked clearly with a completed warranty tag (see Appendix B). Parts
that are not tagged will not be tested, which will result in automatic claim rejection (parts can be
returned to the dealer at their cost). Proper documentation must accompany each shipment, which
includes:
•
Shipping labels marked clearly with Espar reference numbers, affixed to outside of package
(see Appendix C).
Canadian Customers ONLY
Ship to:
Warranty Department
Espar Products, Inc.
6099A Vipond Drive
Mississauga, Ontario
L5T 2B2 CANADA
Espar Reference Number (in this case it is a WE# that has been assigned to you).
U.S. Customers ONLY
Ship to:
Warranty Department
Espar Products, Inc.
60 Industrial Parkway, Suite 730
Cheektowaga, New York
14227 U.S.A.
Espar Reference Number (in this case it is a WE# that has been assigned to you).
NOTE: Tested parts found not to be defective can be returned to a dealer at their request and cost. All parts
are disposed by Espar 30 days after the disposition of the claim has been sent to the dealer.
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“Always Repair Heater” Policy
Espar and Eberspächer have an “Always Repair Heater” policy. In the case that a Main Service Distributor or
Dealer has difficulty in diagnosing and repairing a heater they should contact Espar’s Technical Department
for further assistance. If after consultation with Espar (and providing that it is within its warranty period) and
Espar deems it necessary to have the heater returned, Espar will issue an RR#. This will authorize the heater
to be shipped to Espar for repair. A replacement heater should not be permanently issued to the customer
prior to Espar assisting you with the correct diagnosis of the problem with the heater in question.
Procedure for Submitting a Heater to Espar for Repair Purposes (RR)
1. A request must be made to Espar’s Warranty Supervisor or Technical Department.
2. Espar’s Warranty Supervisor or Technical Department will then issue a “Repair/Rework” (RR)
number.
3. The product may then be returned to Espar with the RR number clearly marked on the shipping label
(Appendix C) and package(s). All costs associated with shipping the heater to Espar will be the
responsibility of the dealer or heater owner. Parts and heaters must be packaged securely to avoid
damage in transit. Parts damaged due to this will not be covered under warranty.
Proper documentation must accompany each shipment, which includes:
•
Shipping labels marked clearly with Espar reference numbers, where applicable, affixed to
outside of package (See Appendix C).
4. Upon receipt, the heater will be tested and, if possible, repaired. If the heater cannot be repaired
(and it is still under warranty), it will be replaced at Espar’s expense. A replacement heater will be
warranted for 90 days or the balance of previous heater’s warranty, which ever is longer.
5. The repaired heater (or new heater, when applicable) will be returned to the dealer or MSD. Shipping
costs (UPS ground) of the return heater to the dealer or MSD will be covered by Espar.
6. If a heater is returned without an RR number, there will be a $50.00 administration charge to your
account. NO EXCEPTIONS WILL BE MADE. In addition, heaters returned with proper authorization
will receive the highest priority for repair.
Canadian Customers ONLY
Ship to:
Warranty Department
Espar Products, Inc.
6099A Vipond Drive
Mississauga, Ontario
L5T 2B2 CANADA
Espar Reference Number (in this case it is a RR# that has been assigned to you).
U.S. Customers ONLY
Ship to:
Warranty Department
Espar Products, Inc.
60 Industrial Parkway, Suite 730
Cheektowaga, New York
14227 U.S.A.
Espar Reference Number (in this case it is a RR# that has been assigned to you).
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New Defective Parts or Heaters (when they are NOT covered under
warranty)
If a new part or heater is determined to be defective by visual inspection, or found to be functionally defective
immediately (PRIOR TO INSTALLATION) it should be returned to Espar using a Return Goods Authorization
Policy(RGA). NEW DEFECTIVE PARTS OR HEATERS CANNOT BE CLAIMED AS WARRANTY.
Procedure for Returning Defective Goods (RGA)
1. A faxed copy of the original invoice or packing slip (with the new, defective part or heater listed on it
must be submitted to the attention of Espar’s Customer Service Department). VERBAL
REQUESTS WILL NOT BE ACCEPTED OR PROCESSED.
2. Espar’s Customer Service staff will in-turn, fax back a Return Goods Authorization (RGA) number.
3. The product may then be returned to Espar with a copy of the Return Goods Authorization (RGA)
form enclosed.
4. Parts and heaters must be packaged securely to avoid damage in transit.
5. Ship via UPS ground (air shipments will not be paid for by Espar).
6. Proper documentation must accompany each shipment, which includes:
•
Shipping labels marked clearly with Espar Reference Number (RGA number affixed to
outside of package). Refer to Appendix C.
Canadian Customers ONLY
Ship to:
Customer Service Department
Espar Products, Inc.
6099A Vipond Drive
Mississauga, Ontario
L5T 2B2 CANADA
Espar Reference Number (in this case it is a RGA# that has been assigned to you).
U.S. Customers ONLY
Ship to:
Customer Service Department
Espar Products, Inc.
60 Industrial Parkway, Suite 730
Cheektowaga, New York
14227 U.S.A.
Espar Reference Number (in this case it is a RGA# that has been assigned to you).
7. Upon receipt, the product will then be inspected and a credit will be processed to the customer of
record (MSD / DD), or may be refused if testing concludes the product is functional. If the product
has been found to be used (installed) the RGA will be rejected, and in turn no warranty claim will be
accepted.
8. When any product is returned without an RGA number there will be a $50.00 administration charge to
your account. NO EXCEPTIONS WILL BE MADE.
17
QSF-60
11.2011
Rev. 4
Procedure for warranty appeal
It is Espar’s intent to close all claims within thirty (30) days after parts are returned and claim process is
completed.
Warranty appeal must be filed within thirty (30) days of claim rejection issue date in order to receive
consideration for reversal.
PLEASE NOTE: Appeals will not be considered for claims that have aged beyond 30 days of final
rejection issue date and closed permanently.
Espar’s Warranty Appeal Process
•
Claim outcome is communicated to the dealer with appeal document attached (Appendix F).
•
Dealer files an appeal to Espar through the Warranty Administrator (Must be within 30 days
claim outcome was communicated to dealer).
•
Warranty Technologist re-opens the claim for re-processing.
•
Warranty Technologist re-evaluates the claim based on the new information from the appeal.
•
If warranty returned part is involved in the appeal, Warranty Technician re-tests the part and
documents a second test report.
•
Based on the report of the second test results, final disposition will be communicated to the
dealer and the claim is closed.
18
QSF-60
11.2011
Rev. 4
The Espar Flat Rate Labour Guide
This flat rate labour guide has been developed from the worldwide experience of Espar and Eberspächer
dealers and distributors.
The flat rate labour guide is organized by heater model in order of heat output.
When submitting a warranty claim, it is mandatory to log a detailed description of the repair. The description
you have provided should correspond to the fault codes indicated. It is imperative to verify replaced parts as
failed parts.
IMPORTANT NOTE:
Espar and Eberspächer have an “Always Repair Heater” policy.
19
QSF-60
11.2011
Rev. 4
AIRTRONIC 2 / 4
For Heater Model Numbers:
AIRTRONIC D2
AIRTRONIC D4
AIRTRONIC B4
Diagram
Reference
Number
25 2069
25 2113
20 1812
25 2070
25 2114
Part Description
Operation
A. Troubleshoot
Flat Rate
Labour
Code
Time
Allowance
(minutes)
A
30
A-B180
A-B230
A-B310
A-B480
A-B540
A-B545
A-B550
A-B565
A-B580
A-B520
A-B010
C
A-C100
A-C050
A-C145
A-C080
10
10
10
10
15
15
10
15
30
30
15
60
10
20
15
10
D
30
Warranty
Authorization
Number (WA#)
Required
B. Components Replaced with Heater Installed
1
Electronic Control Unit (ECU)
2
Combi-Sensor (Overheat / Flame)
3
Glow Pin with Tool
4
Fuel-Metering Pump
5
Mini-Controller
6
Thermostat
7
Rheostat
8
7-Day Timer
9
Main Wire Harness
9
Main Wire Harness
10
Heat Exchanger / Burner
C. Components Replaced with Heater Removed
11
Blower Unit
12
Burner / Flame Tube
13
Gasket, Blower
14
Gasket, Burner
D. Heater Function Test
20
QSF-60
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Replace
Clean
Replace
Replace
Replace
Replace
•
•
11.2011
Rev. 4
AIRTRONIC 2 / 4
21
QSF-60
11.2011
Rev. 4
B/D1LC compact
For Heater Model Numbers:
B1LC compact
D1LC compact
20 1766
25 1976
Diagram
Reference
Number
Part Description
Operation
A. Troubleshoot
Flat Rate
Labour
Code
Time
Allowance
(minutes)
A
30
D1-B180
D1-B480
D1-B540
D1-B545
D1-B550
D1-B565
D1-B330
D1-B525
D1-B530
D1-B535
D1-B580
D1-B520
10
10
15
15
10
15
10
15
15
15
10
10
C
60
D1-C100
D1-C255
D1-C280
D1-C085
D1-C145
D1-C080
D1-C005
D1-C010
D
15
15
15
20
15
20
25
15
30
Warranty
Authorization
Number (WA#)
Required
B. Components Replaced with Heater Installed
1
2
3
4
5
6
7
8
9
10
11
11
Electronic Control Unit (ECU)
Fuel-Metering Pump
Mini-Controller
Thermostat
Rheostat
7-Day Timer
Seal, Glow Plug
Battery Wire Harness
Switch Wire Harness
Fuel-Metering Pump Wire Harness
Main Wire Harness
Main Wire Harness
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Replace
C. Components Replaced with Heater Removed
12
Blower Unit
13
Overheat Sensor
14
Flame Sensor
15
Seal Ring, burner
16
Gasket, Blower
17
Gasket, Burner
18
Heat Exchanger / Burner
18
Heat Exchanger / Burner
D. Heater Function Test
22
QSF-60
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
•
•
•
11.2011
Rev. 4
B/D1LC compact
23
QSF-60
11.2011
Rev. 4
B/D3LC compact
For Heater Model Numbers:
B3LC compact
D3LC compact
20 1767
25 1980
Diagram
Reference
Number
25 1981
Part Description
Operation
A. Troubleshoot
Flat Rate
Labour
Code
Time
Allowance
(minutes)
A
30
D3-B180
D3-B480
D3-B540
D3-B545
D3-B550
D3-B565
D3-B330
D3-B525
D3-B530
D3-B535
D3-B580
D3-B520
10
10
15
15
10
15
10
15
15
15
10
10
C
60
D3-C100
D3-C255
D3-C280
D3-C085
D3-C145
D3-C080
D3-C005
D3-C010
D
15
15
15
20
15
20
25
15
30
Warranty
Authorization
Number (WA#)
Required
B. Components Replaced with Heater Installed
1
2
3
4
5
6
7
8
9
10
11
11
Electronic Control Unit (ECU)
Fuel-Metering Pump
Mini-Controller
Thermostat
Rheostat
7-Day Timer
Seal, Glow Plug
Battery Wire Harness
Switch Wire Harness
Fuel-Metering Pump Wire Harness
Main Wire Harness
Main Wire Harness
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Replace
C. Components Replaced with Heater Removed
12
Blower Unit
13
Overheat Sensor
14
Flame Sensor
15
Seal Ring, Burner
16
Gasket, Blower
17
Gasket, Burner
18
Heat Exchanger / Burner
18
Heat Exchanger / Burner
D. Heater Function Test
24
QSF-60
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
•
•
•
11.2011
Rev. 4
B/D3LC compact
25
QSF-60
11.2011
Rev. 4
B/D5LC
For Heater Model Numbers:
B5LC
D5LC
Diagram
Reference
Number
20 1735
25 1861
25 1862
Part Description
Operation
A. Troubleshoot
Flat Rate
Labour
Code
Time
Allowance
(minutes)
A
30
D5-B175
D5-B180
D5-B480
D5-B545
D5-B550
D5-B555
D5-B565
D5-B330
D5-B525
D5-B530
D5-B535
D5-B580
D5-B520
C
10
5
10
15
10
15
15
10
15
15
15
15
15
60
D5-C100
D5-C085
D5-C270
D5-C280
D5-C515
D5-C090
D5-C145
D5-C080
D5-C005
D5-C010
D5-C130
D
20
25
20
20
20
25
15
20
30
15
20
30
Warranty
Authorization
Number (WA#)
Required
B. Components Replaced with Heater Installed
1
Printed Circuit Board
2
Electronic Control Unit (ECU)
3
Fuel-Metering Pump
4
Thermostat
5
Rheostat
6
Remote Temperature Sensor
7
7-Day Timer
8
Seal, Glow Plug
9
Battery Wire Harness
10
Thermostat Harness
11
Fuel-Metering Pump Wire Harness
12
Main Wire Harness
12
Main Wire Harness
C. Components Replaced with Heater Removed
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Replace
13
Blower Unit
14
Seal Ring, Burner
15
Overheat Switch
16
Flame Sensor
17
Wire Harness, Overheat Switch
18
Cover, Burner
19
Gasket, Blower
20
Gasket, Burner
21
Heat Exchanger / Burner
21
Heat Exchanger / Burner
22
Fan Wheel, Blower Unit
D. Heater Function Test
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Replace
26
QSF-60
•
•
•
•
11.2011
Rev. 4
B/D5LC
27
QSF-60
11.2011
Rev. 4
AIRTRONIC 5
For Heater Model Numbers:
AIRTRONIC B5
20 1859
AIRTRONIC D5
25 2361
Diagram
Reference
Number
25 2362
Part Description
Operation
A. Troubleshoot
Flat Rate
Labour
Code
Time
Allowance
(minutes)
A
30
A5-B180
A5-B480
A5-B540
A5-B545
A5-B550
A5-B565
A5-B580
A5-B520
C
A5-C345
A5-C230
A5-C100
A5-C085
A5-C090
A5-C145
A5-C080
A5-C005
A5-C010
D
10
10
15
10
15
15
30
30
60
15
20
20
25
25
15
20
30
15
30
Warranty
Authorization
Number (WA#)
Required
B. Components Replaced with Heater Installed
1
Electronic Control Unit (ECU)
2
Fuel-Metering Pump
3
Mini-Controller
4
Thermostat
5
Rheostat
6
7-Day Timer
7
Main Wire Harness
7
Main Wire Harness
C. Components Replaced with Heater Removed
8
Cable, Glow Plug
9
Combi-Sensor (Overheat / Flame)
10
Blower Unit
11
Seal Ring, Burner
12
Cover, Burner
13
Gasket, Blower
14
Gasket, Burner
15
Heat Exchanger / Burner
15
Heat Exchanger/Burner
D. Heater Function Test
28
QSF-60
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
•
•
•
11.2011
Rev. 4
AIRTRONIC 5
29
QSF-60
11.2011
Rev. 4
D8LC
For Heater Model Numbers:
D8LC
25 1890
Diagram
Reference
Number
25 1891
Part Description
Operation
A. Troubleshoot
Flat Rate
Labour
Code
Time
Allowance
(minutes)
A
30
D8-B175
D8-B180
D8-B270
D8-B305
D8-B380
D8-B480
D8-B545
D8-B550
D8-B555
D8-B565
D8-B580
D8-B520
D8-B355
D8-B390
D8-B435
D8-B510
10
10
10
10
10
10
15
10
15
15
30
30
5
5
5
15
C
60
D8-C100
D8-C280
D8-C080
D8-C130
D8-C135
D8-C430
D8-C005
D8-C010
D
35
30
15
15
35
20
45
20
30
Warranty
Authorization
Number (WA#)
Required
B. Components Replaced with Heater Installed
1
2
3
4
5
6
7
8
9
10
11
11
12
13
14
15
Printed Circuit Board
Electronic Control Unit (ECU)
Overheat Switch
Temperature Sensor
Air-Solenoid Valve
Fuel-Metering Pump
Thermostat
Rheostat
Remote Temperature Sensor
7-Day Timer
Main Wire Harness
Main Wire Harness
Glow Plug Relay
Relay
Cover, Component Box Housing
Internal Main Wire Harness
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Replace
Replace
Replace
Replace
Replace
C. Components Replaced with Heater Removed
16
Blower Unit
17
Flame Sensor
18
Gasket, Burner
19
Fan Wheel, Blower Unit
20
Housing, Blower Unit
21
Component Box housing with Seal
22
Heat Exchanger / Burner
22
Heat Exchanger / Burner
D. Heater Function Test
30
QSF-60
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
•
•
•
•
•
•
•
•
•
•
11.2011
Rev. 4
D8LC
31
QSF-60
11.2011
Rev. 4
HYDRONIC 4/5 SC
(Integrated Coolant Pump, Integrated Fuel-Metering Pump)
For Heater Model Numbers:
HYDRONIC D4
HYDRONIC D5
Diagram
Reference
Number
25 2257
25 2219
Part Description
Operation
A. Troubleshoot
Flat Rate
Labour
Code
Time
Allowance
(minutes)
A
30
H1-B180
H1-B560
H1-B565
H1-B545
H1-B580
H1-B520
C
H1-C100
H1-C200
H1-C240
H1-C280
H1-C310
H1-C480
H1-C050
H1-C205
H1-C245
H1-C020
H1-C081
H1-C010
H1-C315
D
10
10
15
15
30
30
60
20
15
25
15
15
20
25
15
15
30
25
15
20
30
Warranty
Authorization
Number (WA#)
Required
B. Components Replaced with Heater Installed
1
Electronic Control Unit (ECU)
2
Push/Pull Switch
3
7-Day Timer
4
Thermostat
5
Main Wire Harness
5
Main Wire Harness
C. Components Replaced with Heater Removed
6
Blower Unit
7
Coolant Pump
8
Overheat Sensor With Cable Section
9
Flame Sensor
10
Glow Pin
11
Fuel-Metering Pump
12
Burner / Flame Tube
13
O-Rings, Coolant Pump
14
O-Rings, Sensors
15
O-Ring, Heat Exchanger
16
Seal Kit
17
Heat Exchanger
18
Fuel Connection, Glow Pin
D. Heater Function Test
32
QSF-60
Replace
Replace
Replace
Replace
Repair
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Replace
•
•
•
11.2011
Rev. 4
HYDRONIC 4/5 SC
(Integrated Coolant Pump, Integrated Fuel-Metering Pump)
33
QSF-60
11.2011
Rev. 4
HYDRONIC 4/5 SC
(Integrated Coolant Pump, External Fuel-Metering Pump)
For Heater Model Numbers:
HYDRONIC B4
HYDRONIC B5
HYDRONIC D5
Diagram
Reference
Number
20 1824
20 1820
25 2325
25 2147
Part Description
Operation
A. Troubleshoot
Flat Rate
Labour
Code
Time
Allowance
(minutes)
A
30
H2-B180
H2-B480
H2-B560
H2-B565
H2-B545
H2-B580
H2-B520
10
10
10
15
15
30
30
C
60
H2-C100
H2-C200
H2-C240
H2-C280
H2-C310
H2-C050
H2-C205
H2-C245
H2-C020
H2-C081
H2-C010
H2-C315
20
15
25
15
15
25
15
15
30
25
15
20
D
30
Warranty
Authorization
Number (WA#)
Required
B. Components Replaced with Heater Installed
1
2
3
4
5
6
6
Electronic Control Unit (ECU)
Fuel-Metering Pump
Push/Pull Switch
7-Day Timer
Thermostat
Main Wire Harness
Main Wire Harness
Replace
Replace
Replace
Replace
Replace
Repair
Replace
C. Components Replaced with Heater Removed
7
8
9
10
11
12
13
14
15
16
17
18
Blower Unit
Coolant Pump
Overheat Sensor With Cable Section
Flame Sensor
Glow Pin
Burner / Flame Tube
O-Rings, Coolant Pump
O-Rings, Sensors
O-Ring, Heat Exchanger
Seal Kit
Heat Exchanger
Fuel Connection, Glow Pin
D. Heater Function Test
34
QSF-60
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Replace
•
•
•
11.2011
Rev. 4
HYDRONIC 4/5 SC
(Integrated Coolant Pump, External Fuel-Metering Pump)
35
QSF-60
11.2011
Rev. 4
HYDRONIC 5 S
(External Coolant Pump, External Fuel-Metering Pump)
For Heater Model Numbers:
HYDRONIC B5
HYDRONIC D5
Diagram
Reference
Number
20 1819
25 2217
25 2146
25 2218
Part Description
Operation
A. Troubleshoot
Flat Rate
Labour
Code
Time
Allowance
(minutes)
A
30
H3-B180
H3-B200
H3-B480
H3-B560
H3-B565
H3-B545
H3-B580
H3-B520
10
10
10
10
15
15
30
30
C
60
H3-C100
H3-C240
H3-C280
H3-C310
H3-C050
H3-C205
H3-C245
H3-C020
H3-C081
H3-C010
H3-C315
20
25
15
15
25
15
15
30
25
15
20
D
30
Warranty
Authorization
Number (WA#)
Required
B. Components Replaced with Heater Installed
1
2
3
4
5
6
7
7
Electronic Control Unit (ECU)
Coolant Pump
Fuel-Metering Pump
Push/Pull Switch
7-Day Timer
Thermostat
Main Wire Harness
Main Wire Harness
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Replace
C. Components Replaced with Heater Removed
8
9
10
11
12
13
14
15
16
17
18
Blower Unit
Overheat Sensor With Cable Section
Flame Sensor
Glow Pin
Burner / Flame Tube
O-Rings, Coolant Pump
O-Rings, Sensors
O-Ring, Heat Exchanger
Seal Kit
Heat Exchanger
Fuel Connection, Glow Pin
D. Heater Function Test
36
QSF-60
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Replace
•
•
•
11.2011
Rev. 4
HYDRONIC 5 S
(External Coolant Pump, External Fuel-Metering Pump)
37
QSF-60
11.2011
Rev. 4
HYDRONIC 5 Z
(No Coolant Pump, External Fuel-Metering Pump)
For Heater Model Number:
HYDRONIC D5
Diagram
Reference
Number
25 2216
Part Description
Operation
A. Troubleshoot
B. Components Replaced with Heater Installed
1
Electronic Control Unit (ECU)
2
Fuel-Metering Pump
3
Push/Pull Switch
4
7-Day Timer
5
Thermostat
6
Main Wire Harness
6
Main Wire Harness
C. Components Replaced with Heater Removed
7
Blower Unit
8
Overheat Sensor With Cable
9
Flame Sensor
10
Glow Pin
11
Burner / Flame Tube
12
O-Rings, Coolant Pump
13
O-Rings, Sensors
14
O-Ring, Heat Exchanger
15
Seal Kit
16
Heat Exchanger
17
Fuel Connection, Glow Pin
D. Heater Function Test
38
QSF-60
Replace
Replace
Replace
Replace
Replace
Repair
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Replace
Flat Rate
Labour
Code
Time
Allowance
(minutes)
A
30
H4-B180
H4-B480
H4-B560
H4-B565
H4-B545
H4-B580
H4-B520
C
H4-C100
H4-C240
H4-C280
H4-C310
H4-C050
H4-C205
H4-C245
H4-C020
H4-C081
H4-C010
H4-C315
10
10
10
15
15
30
30
60
20
25
15
15
25
15
15
30
25
15
20
D
30
Warranty
Authorization
Number (WA#)
Required
•
•
•
11.2011
Rev. 4
HYDRONIC 5 Z
(No Coolant Pump, External Fuel-Metering Pump)
39
QSF-60
11.2011
Rev. 4
HYBERNATOR
Hybernator II In Frame
25 2800 10 0530
Diagram
Reference
Number
Part Description
Operation
Flat Rate
Labour Code
A. Troubleshoot
Time
Allowance
(minutes)
A
Warranty
Authorization
Number (WA#)
Required
30
B. Components Replaced with Heater Installed
1
2
3
4
5
6
Hybernator Compact - Controller
Hybernator Water Pump Assembly - FM
Hybernator Compact – Sensor Harness
Hybernator II – Aux FMP Pre Assembly
Fuel Metering Pump B/D5
AF Heat exchanger I-701 - NPT
Replace
Replace
Replace
Replace
Replace
Replace
HB-B185
HB-B200
HB-B307
HB-B481
HB-B480
HB-B011
15
20
10
20
15
20
8
Hybernator II – in Frame Harness
Replace
HB-B581
20
9
Hybernator Compact – Outside Harness
Clean
HB-B582
20
Replace
HB-B531
20
Replace
HB-B532
C
20
60
Replace
H10-B180
10
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Replace
H4-C100
H4-C240
H4-C280
H4-C310
H4-C050
H4-C245
H4-C020
H4-C081
H4-C010
H4-C315
20
25
15
15
25
15
30
25
15
20
D
30
10
Hybernator C System Control Harness
Hybernator Compact – 2 Heater
11
Harness
C. Components Replaced with Heater Removed
Electronic Control Unit (ECU in
11
Hybernator)*
12
Blower Unit
13
Overheat Sensor With Cable
14
Flame Sensor
15
Glow Pin
16
Burner / Flame Tube
17
O-Rings, Sensors
18
O-Ring, Heat Exchanger
19
Seal Kit
20
Heat Exchanger
21
Fuel Connection, Glow Pin
D. Heater Function Test
40
QSF-60
11.2011
Rev. 4
.
.
.
.
•
•
HYBERNATOR
Hybernator Compact
25 2800 10 0515
25 2800 10 0525
Diagram
Reference
Number
Part Description
Operation
A. Troubleshoot
Flat Rate
Labour
Code
Time
Allowance
(minutes)
A
30
Warranty
Authorization
Number (WA#)
Required
B. Components Replaced with Heater Installed
1
2
3
4
5
6
Hybernator Compact - Controller
Hybernator Water Pump Assembly - FM
Hybernator Compact – Sensor Harness
Hybernator II – Aux FMP Pre Assembly
Fuel Metering Pump B/D5
AF Heat exchanger I-701 - NPT
Replace
Replace
Replace
Replace
Replace
Replace
HB-B185
HB-B200
HB-B307
HB-B481
HB-B480
HB-B011
15
20
10
20
15
20
8
Hybernator II – in Frame Harness
Replace
HB-B581
20
9
Hybernator Compact – Outside Harness
Clean
HB-B582
20
10
Hybernator C System Control Harness
Hybernator Compact – 2 Heater
Harness
Replace
HB-B531
20
Replace
HB-B531
20
C
60
Replace
H10-B180
10
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Replace
H4-C100
H4-C240
H4-C280
H4-C310
H4-C050
H4-C245
H4-C020
H4-C081
H4-C010
H4-C315
20
25
15
15
25
15
30
25
15
20
D
30
11
C. Components Replaced with Heater Removed
12
13
14
15
16
17
18
19
20
21
22
Electronic Control Unit (ECU in
Hybernator)*
Blower Unit
Overheat Sensor With Cable
Flame Sensor
Glow Pin
Burner / Flame Tube
O-Rings, Sensors
O-Ring, Heat Exchanger
Seal Kit
Heat Exchanger Clean
Fuel Connection, Glow Pin
D. Heater Function Test
41
QSF-60
.
.
.
.
•
•
11.2011
Rev. 4
HYBERNATOR
Aux Blower Kit
25 2800 90 0019
Diagram
Reference
Number
Part Description
Operation
A. Troubleshoot
Flat Rate
Labour
Code
Time
Allowance
(minutes)
A
30
HB-BK01
20
Warranty
Authorization
Number (WA#)
Required
B. Components Replaced with Heater Installed
HEAT EXCHANGER 201HSS
1
2
3
4
ELECTRIC ACTUATED 3 PORT
VALVE
HYBERNATOR COMPACT BL
SWITCH HARNES
BLOWER POWER HARNESS
B. Function Test
42
QSF-60
Replace
Replace
Replace
Replace
HB-BK02
HB-BK03
.
.
.
.
30
15
HB-BK04
15
B
15
11.2011
Rev. 4
HYBERNATOR
43
QSF-60
11.2011
Rev. 4
HYDRONIC 10
44
QSF-60
11.2011
Rev. 4
For Heater Model Numbers:
HYDRONIC 10
Diagram
Reference
Number
25 2160
25 2227
Part Description
Operation
A. Troubleshoot
Flat Rate
Labour
Code
Time
Allowance
(minutes)
A
30
H10-B180
H10-B480
H10-B560
H10-B565
H10-B545
H10-B580
H10-B520
10
10
10
15
15
30
30
C
60
H10-C100
H10-C200
H10-C255
H10-C280
H10-C305
H10-C310
H10-C205
H10-C265
H10-C295
H10-C020
H10-C050
H10-C055
H10-C010
H10-C911
15
15
15
20
15
10
10
15
15
25
35
35
15
15
D
30
Warranty
Authorization
Number (WA#)
Required
B. Components Replaced with Heater Installed
1
2
3
4
5
6
6
Electronic Control Unit (ECU)
Fuel-Metering Pump
Push/Pull Switch
7-Day Timer
Thermostat
Main Wire Harness
Main Wire Harness
Replace
Replace
Replace
Replace
Replace
Repair
Replace
C. Components Replaced with Heater Removed
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Blower Unit
Coolant Pump
Overheat Sensor
Flame Sensor
Temperature Sensor
Glow Pin
O-Ring, Coolant Pump
O-Ring, Overheat Sensor
O-Ring, Temperature Sensor
O-Ring, Heat Exchanger
Burner / Flame Tube
Burner with Housing
Heat Exchanger
Wire Harness, Glow Pin
D. Heater Function Test
45
QSF-60
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
Replace
•
•
•
•
11.2011
Rev. 4
HYDRONIC 10
46
QSF-60
11.2011
Rev. 4
HYDRONIC M II
For Heater Model Numbers:
HYDRONIC M 8
HYDRONIC M 10
HYDRONIC M 12
Diagram
Reference
Number
25 2470
25 2434
25 2472
25 2471
25 2435
25 2473
Part Description
Operation
Flat Rate
Labour
Code
Time
Allowance
(minutes)
A
30
HM-B200
HM-B205
HM-B440
HM-B480
HM-B535
HM-B560
HM-B565
HM-B570
HM-B580
HM-B520
10
10
15
10
15
10
15
15
30
30
C
60
HM-C201
HM-C050
HM-C080
HM-C150
HM-C185
HM-C241
HM-C280
HM-C310
HM-C450
HM-C006
HM-C010
10
70
70
75
10
35
20
70
30
45
45
D
30
A. Troubleshoot
Warranty
Authorization
Number (WA#)
Required
B. Components Replaced with Heater Installed
1
2
3
4
5
6
7
8
9
10
Coolant pump
O-ring, coolant pump
Relay wire harness
Fuel metering pump
Fuel metering pump wire harness
Push/Pull switch
7 day timer
Programmable timer
Main wire harness
Main wire harness
replace
replace
replace
replace
replace
replace
replace
replace
repair
replace
C. Components Replaced with Heater Removed
1
11
12
13
14
15
16
17
18
19
20
Coolant pump (boxed heater)
1
Burner/Flame tube
Seal, burner
2
Blower/ Control unit
O-ring, blower
Overheat / temperature sensor
Flame sensor
3
Glow pins
Coolant pump wire harness
Heat exchanger / Water jacket
Heat exchanger / Water jacket
replace
replace
replace
replace
replace
replace
replace
replace
replace
replace
clean
D. Heater Function Test
*
*
*
*
1 – burner tube replacement includes replacement of burner seal and blower O-ring
2 – blower/control unit replacement includes replacement of blower O-ring and burner seal
3 – glow pin replacement includes replacement of blower O-ring and burner seal
47
QSF-60
11.2011
Rev. 4
HYDRONIC M II
48
QSF-60
11.2011
Rev. 4
HYDRONIC 16 / 24 / 30 / 35
For Heater Model Numbers:
HYDRONIC 16
HYDRONIC 24
HYDRONIC 30
HYDRONIC 35
25 2165
25 1817
25 1818
25 1819
Diagram
Reference
Number
Part Description
Operation
A. Troubleshoot
Flat Rate
Labour
Code
Time
Allowance
(minutes)
A
30
LH-B200
LH-B255
LH-B305
LH-B560
LH-B565
LH-B225
LH-B580
LH-B520
LH-B450
LH-B510
10
10
10
10
15
20
30
30
10
5
C
90
LH-C050
LH-C105
LH-C165
LH-C170
LH-C180
LH-C195
LH-C335
LH-C500
LH-C505
LH-C155
LH-C495
LH-C006
LH-C010
5
10
10
10
10
10
10
15
15
5
20
20
20
D
30
Warranty
Authorization
Number (WA#)
Required
B. Components Replaced with Heater Installed
1
2
3
4
5
6
7
7
8
9
Coolant Pump
Overheat Sensor
Temperature Sensor
Push/Pull Toggle Switch
7-Day Timer
Spare Part Kit, Coolant Pump
Main Wire Harness
Main Wire Harness
Combustion-Air Inlet Hood
Internal Main Wire Harness
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Replace
Replace
Replace
C. Components Replaced with Heater Removed
10
11
12
13
14
15
16
17
18
19
20
21
21
Flame Tube
Burner Motor
Fuel Atomizer Nozzle
Heat Element, Nozzle
Electronic Control Unit (ECU)
Ignition Spark Generator
Ignition Electrodes
Fuel Solenoid Coil
Hardware for Fuel Solenoid Coil
Baffle Plate / Heat Shield
Fuel Pump / Housing
Heat Exchanger / Water Jacket
Heat Exchanger / Water Jacket
D. Heater Function Test
49
QSF-60
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
•
•
•
•
•
•
11.2011
Rev. 4
HYDRONIC 16 / 24 / 30 / 35
50
QSF-60
11.2011
Rev. 4
HYDRONIC L II
For Heater Model Numbers:
HYDRONIC L 16
HYDRONIC L 24
HYDRONIC L 30
HYDRONIC L 35
Diagram
Reference
Number
25 2486
25 2487
25 2488
25 2489
Part Description
Operation
A. Troubleshoot
Flat Rate
Labour
Code
Time
Allowance
(minutes)
A
30
HL-B200
HL-B255
HL-B305
HL-B560
HL-B565
HL-B225
HL-B580
HL-B520
HL-B450
HL-B510
10
10
10
10
15
20
30
30
10
5
C
90
HL-C050
HL-C105
HL-C165
HL-C170
HL-C180
HL-C195
HL-C335
HL-C501
HL-C155
HL-C490
HL-C006
HL-C010
5
10
10
10
10
10
10
15
5
40
20
20
D
30
Warranty
Authorization
Number (WA#)
Required
B. Components Replaced with Heater Installed
1
2
3
4
5
6
7
7
8
9
Coolant Pump
Overheat Sensor
Temperature Sensor
Push/Pull Toggle Switch
7-Day Timer
Spare Part Kit, Coolant Pump
Main Wire Harness
Main Wire Harness
Combustion-Air Inlet Hood
Internal Main Wire Harness
Replace
Replace
Replace
Replace
Replace
Replace
Repair
Replace
Replace
Replace
C. Components Replaced with Heater Removed
10
11
12
13
14
15
16
17
18
19
20
20
Flame Tube
Burner Motor
Fuel Atomizer Nozzle
Heat Element, Nozzle
Electronic Control Unit (ECU)
Ignition Spark Generator
Ignition Electrodes
Fuel Solenoid Valve
Baffle Plate / Heat Shield
1
Fuel Pump Kit
Heat Exchanger / Water Jacket
Heat Exchanger / Water Jacket
D. Heater Function Test
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
•
•
•
•
•
•
1- fuel pump kit replacement includes replacement of nozzle heat element and fuel atomizer nozzle
51
QSF-60
11.2011
Rev. 4
HYDRONIC L II
52
QSF-60
11.2011
Rev. 4
Tools and Equipment
Generally, standard shop tools are required for the installation and repair of Espar heaters.
However, there are a few additional tools required for efficient troubleshooting and repair. All
required tools are listed below.
REQUIRED Equipment for General Heater Repair
•
•
•
•
•
•
•
•
•
•
Diagnostic Unit
- Previously named “Fault Code Retrieval Device”
- Appropriate diagnostic wire adaptors
Electrician’s crimping tool for non-insulated terminals
Terminal Removal Tool, 1.6mm
Terminal Removal Tool, 2.8mm
3
Graduated cylinder, range of 0 to 50cm or 0 to 50ml
Torx drivers
Metric Allen key wrenches
Metric wrenches and / or sockets (4mm through 27mm)
Fuel line cutter or knife
Multi-meter
For complete and thorough service of Espar heaters, the following special tools and equipment
are recommended in addition to those listed above.
Special Tools
•
•
•
•
•
•
•
•
EDiTH diagnostic computer software and hardware
3
Graduated cylinder, range of 0 to 500cm (for HYDRONIC 16 / 24 / 30 / 35, )
Spark gapping gauge(s) for HYDRONIC 16 / 24 / 30 / 35
Tachometer (RPM meter), optical or digital readout preferred
Stopwatch
Thermometer, minimum range of 0°C to 300°C (32°F to 572°F)
Carbon dioxide (CO2) gas analyzer, minimum range of 0 to 20%
Smoke Tester
53
QSF-60
11.2011
Rev. 4
Computer Diagnostic Tool - EDiTH
The following overview is there to help you understand the capability of different diagnostic
hardware. Available are: Diagnostic Unit, EDiTH Basic and EDiTH Expert.
Product/
Functions
Diagnostic
Unit
Read out of the current error and the
latest 5 errors
Running diagnosis at installed heaters
Turn on the heater directly by PC or
Notebook
Visualization of the sequence of
operations of the heater/control unit with
display of the operating state and
measured data of each components →
components test
Individual test of components
(independent of the control unit) ie.
voltage of glow pin, voltage and speed of
el. motor, fuel metering pump
Recognition if heater is high attitude
adjustable
Display of general heater data
IPCU programming
Recognition if the control unit is high
altitude adjustable
Running diagnosis on control unit
Test control unit under real performance
conditions
EDiTH
Basic
EDiTH
Expert
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
In addition to EDiTH Basic and Expert hardware, additional adapter cables are required for each
type of heater installation. Type of adapters will depend on heater model and installation. For list
of Adaptors and their part numbers please refer to current Espar Product Catalogue.
EDiTH software is updated regularly and the most recent version should be downloaded and
installed from www.espar.com/help.
54
QSF-60
11.2011
Rev. 4
APPENDIX A
The Espar Limited Warranty
Espar Products Inc. (“Espar”) warrants its heaters (the “Products”) to be free from defects in materials and workmanship,
subject to the terms below.
Espar will, at its option, repair or replace any Products or any parts of a Product which are subject to warranty according
to Espar’s Warranty Manual (the “Warranted Parts”), if such Products or Warranted Parts are proven defective in
materials or workmanship during the relevant warranty period (the “Warranty Period”) described below. This is Espar’s
sole obligation under this warranty.
This warranty extends only to the original owner (each an “Owner”). Unless Espar agrees in writing, this warranty cannot
be transferred and it only applies to a Product in its original installation.
The Warranty Period is: (a) two (2) years or two thousand (2000) operating hours (whichever comes first) for AIRTRONIC
2, AIRTRONIC 4, AIRTRONIC 5, B1LC compact, B/D3LC compact, HYDRONIC 4, HYDRONIC 5 and B/D5W heaters; or
(b) two (2) years or one thousand five hundred (1500) operating hours (whichever comes first) for HYDRONIC MII
heaters; or (c) one (1) year or one thousand (1000) operating hours (whichever comes first) for all other Espar heaters.
The Warranty Period begins on: (a) the date of sale of equipment containing the Product by an Original Equipment
Manufacturer (“OEM”) to the Owner; or (b) the date of installation for the Owner or the date of shipment by Espar,
whichever is later, for all Products not sold to an Owner by an OEM.
To obtain service of a Product under this warranty, present the nearest Espar authorized and trained dealer (each an
“Espar Dealer”) with proof of purchase and for Products not sold by an OEM, the date of installation. To establish the
date of purchase and date of installation of a Product, Owners should register for the Espar Warranty on-line at
www.espar.com within thirty (30) days of the installation or purchase of the Product. If the Owner has not registered
online, the Owner can submit to the Espar Dealer other reasonable proof of the dates of purchase and for Products not
sold by an OEM, of product installation. If the Owner cannot prove such dates, the Warranty Period will be deemed to
have started when the Product was shipped by Espar.
The Espar Dealer will perform warranty service subject to this warranty and Espar’s Warranty Manual. The Espar Dealer
will also complete and submit a Warranty Claim to Espar. Espar will pay only Espar Dealers or installers to remove and
re-install Products and Warranted Parts according to Espar’s Warranty Manual. Espar shall not pay for any other labour
costs.
Depending on where and how the Product was installed, the Owner may be required to return the Product to the Espar
Dealer who originally installed the Product for warranty service. The cost of this return will be paid by the Owner. When
servicing according to this warranty, Espar or an Espar Dealer may replace parts with new parts and change part
specifications without notice provided such replacements or changes do not adversely affect the Product’s performance.
This warranty does not cover damage or defects caused by: (a) installation; (b) service; (c) the use of replacement parts
which are not genuine Espar parts; (d) use of a Product for other than its intended purpose; (e) use under other than
normal conditions; (f) use contrary to Espar’s instructions; (g) accident; (h) neglect; or (i) normal wear and tear on parts
such as glow plugs, atomizer screens, fuel filters, fuses, lamp bulbs, intake and exhaust tubing and ducting.
THIS WARRANTY IS IN LIEU OF ALL OTHER EXPRESSED OR IMPLIED WARRANTIES. ESPAR’S LIABILITY FOR
DAMAGES IS LIMITED TO THE COST OF REPLACING THE PRODUCT. ESPAR SHALL NOT BE LIABLE FOR
SPECIAL, INCIDENTAL, PUNITIVE OR CONSEQUENTIAL DAMAGES.THIS IS ESPAR’S ENTIRE WARRANTY. IT
CAN ONLY BE CHANGED WITH THE EXPRESS WRITTEN CONSENT OF ESPAR.
THIS WARRANTY SHALL BE INTERPRETED AND GOVERNED BY THE LAWS OF THE PROVINCE OF ONTARIO,
CANADA REGARDLESS OF WHERE THE PRODUCT IS SOLD OR INSTALLED. ANY LEGAL ACTION REGARDING
THIS WARRANTY SHALL ONLY BE COMMENCED IN THE SUPERIOR COURT OF JUSTICE IN ONTARIO. THE
PARTIES EXPRESSLY WAIVE ANY RIGHT TO A TRIAL BY JURY.
If you have any questions about this warranty, please contact Espar’s Warranty Manager at Espar Products Inc., 6099A
Vipond Drive, Mississauga ON L5T 2B2. For our Warranty Manual, please visit our website at www.espar.com.
55
QSF-60
11.2011
Rev. 4
APPENDIX B
Sample of Warranty Tag
56
QSF-60
11.2011
Rev. 4
APPENDIX C
Sample of Espar Shipping Label
57
QSF-60
11.2011
Rev. 4
APPENDIX D
Warranty Notification Form
Warranty Claim #
Date
Serial #
Model #
Warranty Claim is ON HOLD: Additional information is required by Espar to process the
warranty claim. Please submit the following information to Espar’s Warranty Department within
10 business days from the date on this form.
Installation documentation required to prove applicable warranty period (as warranty was not
registered).
Further technical information required to support repair.
Other
Comments:
Adjustments were made to the submitted Warranty Claim:
Labour time requested is higher than the Flat Rate Labour Guide allows.
Duplicate labour codes.
Warranty Authorization for excess time, labour or parts was not requested and/or authorized
by Espar’s Warranty Department.
Parts returned for inspection were tested and found to be free of defects.
Comments:
Rejection of the Warranty Claim:
Heater warranty period has expired.
Parts returned for inspection were tested are found to be not defective.
Parts claimed are not covered under warranty.
Inadequate Parts Return
Duplicate Warranty Claim submitted.
Vehicle owner on Warranty Claim is not the original registered owner (warranty nontransferable).
Requested information to support warranty claim was not received within 10 business days.
Unauthorized WA # used for warranty claim that is not approved for this serial number.
Comments:
Acceptance of the Warranty Claim:
Warranty claim has been approved.
58
QSF-60
11.2011
Rev. 4
APPENDIX E
Technician’s Checklist
Technician’s Checklist
Work Order: _______________________
Heater Model: _________________
Serial Number: _____________________
EDiTH Information
ITEM CHECK
AF
F1
F2
F3
Overall Heater Run Time:
Installation position on vehicle:
Fuel pump mounting position:
Fuel quantity test (before removal)
Unit is boxed?
Check Performed
Technician: ____________________
YES
Found
(YES/NO)
Electrical System
F4
F5
# of Starts:
NO
Action Taken
Are connections tight and free of
corrosion?
Has proper gauge wiring been used for the
length and amperage requirements?
Have any fuses/circuit breakers been
activated?
Is power taken directly from batteries and
ground to the batteries?
Coolant Flow / Air Flow System
Are there any obstructions in the system?
Is the heater system too large/small for the
application?
Has proper coolant hose size or ducting
been used?
Fuel System
Have proper diameter fuel lines been
used?
Have proper length fuel lines been used?
Has a proper connection to the fuel supply
been made?
Is the fuel flowing freely? (fuel is not gelled)
Are there restrictions in the fuel line?
Is the fuel metering pump properly aligned?
Is the fuel filter clogged?
APPENDIX F
59
QSF-60
11.2011
Rev. 4
60
QSF-60
11.2011
Rev. 4
61
QSF-60
11.2011
Rev. 4